Articulated surgical tool

ABSTRACT

An articulated surgical tool and method of use are provided. The articulated surgical tool may hold an instrument and a surgical tool and may provide both macro and micro motions in the instrument and/or surgical tool, including by hydraulic operation. The articulated surgical tool may be coupled to a control system, such that manipulation of the control system results in movement of instrument and/or surgical tool, thereby eliminating the need to manually hold and position the instrument and/or surgical tool.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority to U.S. Provisional Application No. 61/237,042, which was filed on Aug. 26, 2009. This application is also related to applicants' co-pending U.S. Provisional Patent Appl. No. 61/297,630 titled “HYDRAULIC DEVICE INCLUDING SPOOL VALVE,” filed Jan. 22, 2010 and U.S. Provisional Patent Appl. No. 61/298,714 titled “OVERFORCE MECHANISM” filed Jan. 27, 2010, of which the entirety of each are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to mechanical devices and mechanical devices involving hydraulic actuation. The present invention also relates to hand or otherly actuated articulating devices, hydraulic devices or otherwise. One aspect of the present invention relates to a hand or otherly actuated articulating surgical instrument for use in minimally invasive surgical procedures or other procedures involving remote actuation.

2. Background of the Related Art

Hydraulic systems for applications in laparoscopic surgical tools, as well as tools for other surgical procedures, are known. Current laparoscopic surgical instruments typically have considerable limitations, however, including difficulties in accessing portions of the body obstructed by organs or other objects, difficulties in sterilizing all or portions of such tools, and difficulties in ease of use. Further, while such existing laparoscopic surgical instruments can perform invasive surgical procedures, the instruments are often awkward to manipulate and have problems performing complicated movements often necessary in surgery. In particular, such instruments can be difficult to manipulate around corners, obstacles and to use in obstructed or otherwise difficult to reach environments.

In addition, existing laparoscopic surgical instruments may either have a fairly limited range of motion and/or are not capable of performing certain sophisticated and delicate operations or motions with precision. Further, such instruments may also be fairly limited in their flexibility to accommodate unexpected or unanticipated motion. Also, existing laparoscopic surgical instruments often lack an intuitive connection between motion initiated by the user in the control portion of the device and corresponding motion actuated remotely in the slave portion of the device.

Moreover, existing laparoscopic surgical instruments typically use cables and hydraulic lines to manipulate the surgical tip of the instruments. The hydraulics often require the use of special hydraulic fluid that is not necessarily amenable to surgical environments or other special environments. For example, the use of conventional hydraulic oils in surgical environments is ill-advised and may create an assortment of hazards, especially if the system leaks or the hydraulic conduits are prone to rupture. While more medically compatible hydraulic fluid may be used (e.g., water, mineral oils, etc.), such fluid tends to evaporate at a significant rate. Monitoring and replenishing such fluid manually can be costly and labor intensive. Further, the consequences of not being vigilant concerning fluid levels could be severe, particularly in a surgical environment.

In addition, the tools used by the device can be expensive and difficult to clean and sterilize. Since the cleaning and sterilization procedure must be performed after each use, any expense incurred can substantially add to the cost of use of the device. Alternatively, if disposable tools are used, the need for their continual replacement can add to the cost of the overall system. Also, disposable tools may be made from less robust materials as those meant for multiple uses, leading to increased potential for problems due to equipment malfunction and/or fracture.

Moreover, laparoscopic surgical instruments using cables and hydraulic lines to remotely manipulate the surgical tip of the instruments can be vulnerable to accidental misuse or user overcompensation sometimes due to a lack of direct tactile feedback. This danger is especially significant when the apparatus is not in deliberate use (e.g., when the device is dormant during a critical portion of surgery where other equipment is being used), is being serviced/stored or is not being operated by a skilled practitioner. Inadvertent and potentially damaging maneuvers are possible, for example, when the device is moved in between operating theaters or when routine maintenance is being performed. In particular, problems can arise when a user moves a control for a laparoscopic surgical device in such a way that can cause damage either to the device itself, to ancillary devices and/or to the patient.

Thus, there is a need in the art for an improved surgical system.

SUMMARY OF THE INVENTION

While discussion of the aspects of the present invention that follows uses surgery for an illustrative purpose, it should be appreciated that the environment of the present invention is not limited to surgery and may be used in a variety of other environments. For example, aspects of the present invention may be used in manufacturing, construction, assembly lines, handling and disposing of hazardous materials, underwater manipulations, handling high temperature materials, or any other environment where a user may be remote from the item being manipulated or may experience fatigue when operating a mechanical device.

In one aspect, a manually-actuated, direct feedback, articulating surgical instrument provides a user with an increased degree of freedom of motion and allows the user to access that increased degree of freedom of motion in manner that is intuitive.

In another aspect, a manually-actuated, direct feedback articulating surgical device utilizes a clutch mechanism to shunt accidental overforce motion by the user in such a way as to prevent damage to the device, patient or other entities.

In a further aspect, a manually-actuated, direct feedback articulating surgical instrument is provided that is capable of being easily manipulated around corners and other such hard to reach places.

Aspects of the present invention aid a user, for example, a surgeon or other such medical practitioner, in manipulating an articulating surgical instrument by providing a manually-actuated, input system to remotely control an articulating surgical device and/or tool. In some aspects, such remote manual actuation may include one or any combination of hand, finger, forearm or arm movements. Further, such manual actuation may drive a remotely situated articulating device, including a tool for performing work, such as surgery, in a remote area or field. The manual actuation may be transmitted to the remotely situated device via a hydraulic system. The hydraulic system provides the user with direct feedback from the remotely-situated device and/or tool, thereby providing the user with a “feel” of the remote environment, thereby simulating direct user input. For example, the hydraulic provides feedback of the friction and resistive forces corresponding to the remote motion of the actuated articulating surgical instrument within the patient.

In one aspect of the present invention, a surgeon inputs a force at a control portion of the system, causing a slave portion including the surgical instrument to move in a direction controlled by the inputted force. In particular, hydraulic or other components translate the user's input motion into hydraulic pressure and transmit the hydraulic pressure to other portions of the device. The other portions of the device then employ hydraulic components to translate the hydraulic pressure into motion of various surgical or other implements. The arrangement of the hydraulics and the articulating surgical instrument can provide an enhanced range of motion.

Further, for example, in another aspect of the present invention, the hydraulic system allows a user to remotely actuate one or more motions, thereby providing a surgical instrument with multiple degrees of freedom. The degrees of freedom may include combinations of macro motions and micro motions. The macro motions may include one or more of: translation, rotation, swiveling and extension/retraction. The relatively fine micro motions include relatively smaller scale movements of the surgical instrument and/or tool, such as grasping using the tip of the tool, rotating the tip of the tool, bending the “wrist” of the tool and rotating the “forearm” of the tool. The remote actuation may include any combination of macro and micro motions that may position the surgical instrument and/or tool in order to increase access to a working, environment or theater of operation. Additionally, in an aspect, the present system provides a direct correlation between inputs at the control portion of the system and Movements of the surgical instrument and/or tool. In other words, both the control portion and the surgical instrument and/or tool move in the same direction, although the relative motion of each may vary by a given ratio, which may be varied depending on system design.

In yet another aspect of the invention, a hydraulic system that allows a user to remotely actuate various motions in an operating environment also includes a clutch mechanism. The clutch mechanism may, among other things, disengage the user controls from the remotely actuated portion of the system to avoid unnecessary, unwanted and potentially damaging inadvertent motion.

Aspects of the present invention provide one or more benefits and advantages, such as a remotely actuated mechanical system with increased degrees of freedom. Thus, complicated motions, procedures and operations can be performed in locations distant from or removed from the user. Further, multiple degrees of freedom of motion of a surgical instrument and/or tool can be provided to the user in a manner that includes direct tactile feedback, and with a direct correlation between user and instrument/tool movements. As such, aspects provide an intuitive connection between user motions in the control portion and resultant movements of the slave portion of the system.

Aspects of the present invention provide benefits and advantages that also include the ability to compensate for friction and unwanted resistance that occurs when manipulating the surgical instrument within a patient. For example, by providing the ability to set the ratio of input force or movement to output force or movement, a small input can be translated into a relatively larger output. Thus; manipulating the surgical instrument within the patient is easier to accomplish and fatigue experienced by the surgeon is reduced. Additionally, the present invention creates a smooth force enhancement response to the motion inputted by the surgeon.

Aspects of the present invention aid the surgeon in manipulating the surgical instrument in the direction of the motion inputted by the surgeon. Moreover, the present invention is capable of achieving a high degree of articulation, thus being easier to manipulate around corners and function in hard to reach places.

Additional advantages and novel features relating to the present invention will be set forth in part in the description that follows, and in part will become more apparent to those skilled in the art upon examination of the following or upon learning by practice of aspects of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become fully understood from the detailed description given herein below and the accompanying drawings, which are given by way of illustration and example only and thus not limited with respect to aspects of the present invention, wherein:

FIG. 1A is a schematic diagram of one aspect of an exemplary device for remotely controlling an instrument or tool in a work environment;

FIG. 1B is a slave end view of one aspect of a manually-actuated, remote surgical system including a control portion that receives inputs to drive a slave portion, for example, to control an instrument or tool in a work environment;

FIG. 1C is a side view the slave portion of FIG. 1A;

FIG. 1D is a front view of the system of FIG. 1A including additional components, including an additional control portion that may be used to drive an additional slave portion;

FIG. 2A is a detailed drawing of a side view of one variation of an exemplary control portion that may be used in conjunction with the present invention;

FIG. 2B is a detailed side view of an opposite side of the exemplary control portion shown in FIG. 2A;

FIG. 3A is a side view of the micro controls 50 a of the exemplary control portion shown in FIG. 2A;

FIG. 3B is a front perspective view of the control portion of FIG. 3A in use;

FIG. 4A is a side view of the macro controls 50 b of the exemplary control portion shown in FIG. 2A;

FIG. 4B is a side view of an opposite side of the macro controls 50 b of the exemplary control portion shown in FIG. 4A;

FIGS. 4C and 4D are a side view and a front perspective view, respectively, of the macro controls in FIGS. 4A and 4B in use;

FIGS. 5A and 5B are schematic views of one aspect of an exemplary mechanism that may allow actuation of a control cylinder;

FIGS. 6A and 6B are side perspective views of aspects of the slave portion of the present invention;

FIG. 7 is a perspective view of another aspect of the slave and control portions of the present invention;

FIG. 8 is a side view of the device in FIG. 7;

FIG. 9 is a side view from a side opposite from the view in FIG. 8;

FIG. 10 is a top view of the slave and control portions of the device of FIG. 7;

FIG. 11 is a bottom view of the slave and control portions of the device of FIG. 7;

FIG. 12A is a perspective view of an aspect of the slave portion of the present system, illustrating an overview of three exemplary macro degrees of freedom of the slave portion;

FIG. 12B is a side view of an aspect of the control portion of the system, illustrating an overview of how the three exemplary macro degrees of freedom shown in FIG. 12A may be actuated in the control portion;

FIG. 13A is a side view of an aspect of the control portion of the system, including a clutch safety mechanism that may be part of the macro controls in variations of the invention;

FIG. 13B is a side view of a close up of the clutch safety mechanism of FIG. 13A from the opposite side;

FIGS. 14A-14C are side views of the control portion of the system, illustrating how an exemplary forward/reverse pivoting motion may be actuated by the macro controls in accordance with aspects of the present invention;

FIGS. 14D and 14E are perspective views of parts of the slave portion of the system, illustrating a resultant exemplary forward/reverse pivoting motion in the slave portion that may be actuated by the motion shown in FIGS. 14A-14C;

FIG. 14F is a close-up side view of a curved track part of the slave portion of the system, illustrating the exemplary forward/reverse pivoting motion along the curved track of the slave portion shown in FIGS. 14D and 14E;

FIGS. 15A and 15B are partial perspective views of the slave portion of the system, illustrating the exemplary forward/reverse pivoting motion of the tool of the slave portion that may be actuated by the motion shown in FIGS. 14A-14C;

FIGS. 16A-16C are a top view, a top view and a side view, respectively, of the control portion, illustrating how an exemplary lateral swivel motion may be actuated by the macro controls in accordance with aspects of the present invention;

FIGS. 16D and 16E are perspective views of the slave portion illustrating a resultant exemplary lateral swivel motion in the slave portion that may be actuated by the motion shown in FIGS. 16A-16C;

FIG. 16F is a perspective view of an exemplary screw mechanism that may actuate the exemplary lateral swivel motion shown in FIGS. 16D and 16E;

FIGS. 17A-17C are partial side views of the control portion illustrating how an exemplary extension/retraction motion may be actuated by the macro controls in accordance with aspects of the present invention;

FIGS. 17D and 17E are side perspective views of an exemplary extension/retraction motion in the slave portion that may be actuated by the motion shown in FIGS. 17A-17C;

FIG. 18A is a side view of an exemplary tool of a slave member to illustrate various articulated motions in accordance with aspects of the present invention.

FIG. 18B is a perspective side view of an exemplary micro control to illustrate various articulated motions in accordance with aspects of the present invention;

FIG. 19 is a perspective view of an exemplary micro controls for use with a hand articulated control system;

FIG. 20 is a side view of the exemplary micro controls for use with a hand articulated control system;

FIG. 21 is a side perspective view of the exemplary micro controls for use with a hand articulated control system;

FIG. 22 shows is a top view of the exemplary micro controls for use with a hand articulated control system; and

FIG. 23 shows an exemplary computer system that may be used in conjunction with aspects of the present invention.

DETAILED DESCRIPTION OF ASPECTS OF THE PRESENT INVENTION

Aspects of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which variations and aspects of the present invention are shown. Aspects of the present invention may, however, be realized in many different forms and should not be construed as limited to the variations set forth herein; rather, the variations are provided so that this disclosure will be thorough and complete in the illustrative implementations, and will fully convey the scope thereof to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which aspects of the present invention belong. The methods and examples provided herein are illustrative only and not intended to be limiting.

Overview of Components of the Present Invention

FIG. 1A is a schematic diagram of one aspect of an exemplary device or system 1 for remotely controlling an articulating instrument 4 and/or tool 7 in a work environment O, for example, for performing surgery on a patient. Although the specific aspects of the device may vary according to the application, FIG. 1 shows the general overview of this type of device 1.

The device 1 may include a control portion 50 operable to receive an input 3, such as a force or motion, to drive the instrument 4 and/or tool 7 connected to a slave portion 70 of the device. The input 3 is transferred from the control portion 50 to the slave portion 70 via a transfer mechanism 5, such as a hydraulic system. Device 1 may be configured to provide a given correlation between input 3 and the resultant output 11 that operates instrument 4 and/or tool 7 within an operational environment O. For example, input 3 may be a linear and/or rotational movement, and output 11 may be a linear and/or rotational movement, and such movements may be combined or correlated in any fashion. For instance, a linear input 3 may be correlated to an output 11 that is linear or rotational, and a rotational input 3 may be correlated to an output 11 that is rotational or linear. Also, the relative degree of transfer may be controlled, e.g. such that a given amount of input 3 produces a given amount of output 11. Further, transfer mechanism 5 may additionally transfer feedback from instrument 4 and/or tool 7 back to control portion 50, thereby providing a user with a direct, tactile feel for the work being performed by the instrument 4 and/or tool 7. In one example of a suitable application for system or device 1, the instrument 4 and/or tool 7 may include an articulating device for performing surgery within a portion of a body of a patient. Thus, device 1 provides a system to control, in a precise manner, actions of an instrument 4 and/or tool 7 in an operational environment O from a remote location.

Variations of aspects of the invention implemented in devices and systems, such as device 1 as well as others, may include a variety of possible movements and motions in both the control and slave portions. Herein, the ability to produce such motions in a device will be described as a “degree of freedom” or “providing a degree of freedom.” The term “degree of freedom” is not meant to be used in a strict mathematical or physical sense. Rather, a “degree of freedom” is meant to refer to a certain motion or category of motions that are allowed in the control, slave or other portions of the device or system. One skilled in the art will understand that the systems and devices discussed herein are not limited to the degrees of freedom explicitly described herein. Rather, the devices and systems described herein may be reconfigured even without adding new components such that additional degrees of freedom are included. Further, new components may also be added to devices and systems described herein in order to facilitate new degrees of freedom or to change the scope, direction or other aspect of degrees of freedom discussed herein. Further, the devices and systems discussed herein may also be reconfigured in ways that preserve the degrees of freedom discussed herein. It is to be understood that all such changes are within the scope of the invention and that each of the devices, systems, configurations and degrees of freedom discussed is merely exemplary.

Generally speaking, a large-scale movement that translates multi-functional portions of the device will be referred to as a “macro” movement. However, it is to be understood that this term is not rigorous. For example, macro movements are possible for uni-functional aspects of the device. Macro movements are generally employed for relatively large-scale positioning of the instrument and/or tool closer to or further away from the operational environment 9, although macro movements can be employed for other purposes as well. Each macro movement is considered a degree of freedom.

Generally speaking, a small-scale movement that translates a uni-functional portion of the device will be referred to as a “micro” movement. However, it is to be understood that this term is not rigorous. For example, micro movements are possible for multi-functional aspects of the device. Micro movements are generally employed for moving the instrument 4 and/or tool 7 within the operational environment 9 in order to perform specific operations. However, it is to be understood that micro movements can be employed for other purposes as well. Each micro movement is considered a degree of freedom.

Further, in device 1, the control portion 50 is capable of actuating both macro and micro movements and the slave portion 70 is capable of carrying out both macro and micro movements. Generally, these portions are connected via transfer mechanism 5, such as hydraulic lines. The control portion can provide a user interface to allow actuation of aspects of the slave portion or portions via the hydraulic lines or other mechanisms. Although a particular configuration for the control and slave portions is shown in FIG. 1A, it is to be understood that this is merely one exemplary configuration. As well be shown, several variations of the control and slave portions are part of this invention and variations not shown or discussed herein may also be used in conjunction with aspects of the invention.

FIG. 1B shows a variation of a control portion 50 and slave portion 70, and FIG. 1C a more detailed view of the variation of slave portion 70, of on exemplary device 1000 according to aspects of the present invention. FIG. 1D shows another view of the control and slave portions of FIGS. 1B and 1C, respectively. As shown in FIG. 1B, a user U may operate the control portion 50 by grasping a grasper hand assembly 1200. The grasper hand assembly 1200, and the control portion 50 in general, may have various levers, triggers and/or other actuators. These levers, triggers and/or other actuators are usually connected via a transfer mechanism, such as hydraulic lines, to various parts of the slave portion 70 of the device. For example, FIGS. 1B, 1C and 1D include an instrument 4 on the end of the slave portion 70 of the device that may be actuated using the control portion 50 and associated hydraulic systems so that it operates in the operational environment O (FIGS. 1C and 1D). For example, pulling a trigger on the grasper hand assembly 1200 may extend the instrument 4 in the direction towards the operational environment O. Alternatively, the instrument 4 may have a number of functionalities (e.g., cutting, grasping, gouging, and piercing) that may be actuated by the trigger or other portions of the grasper hand assembly 1200. Multiple instruments 4 and/or tools 7 may also be configured for use in the slave portion 70, examples of which will be explored in greater detail below. The operational environment O may be a surgical operating environment or it may be one of the other exemplary environments mentioned herein in the context of device 1000, as well as any of the other devices and variations of the present invention.

FIGS. 1C and 1D also show an adjustable stand 2 that may be used to fix the control portion 50, the slave portion 70 or both to a particular location or object. For example, the stand 2 may be fixed to a side of a table in an operating room. Alternatively, the stand 2 may be a self-standing apparatus for supporting the device 1 in any suitable location. As such, the stand 2 may also be fixed in other locations, such as in an environment where mechanical or electrical work is to be done. The stand 2 may include various components that allow different parts of the device 1000 to be adjustably positioned at various locations. For example, FIGS. 1C and 1D show a series of grip handles 2 a and knobs 2 b that may be used to alternatively fix and release various posts and beams 2 c providing support to parts of the device 1000. In addition, the beams 2 c, or other components, may be connected to each other or to other objects using vices, crimpers or clamps 2 d. It is to be understood that the structure for the adjustable stand 2 shown in FIGS. 1C and 1D is merely representative. In fact, the structure of the stand 2 can be reconfigured, rebuilt and/or adjusted as needed.

FIG. 2A is a detailed drawing of a side view of one variation of an exemplary control portion 50 that may be used in conjunction with the present invention. FIG. 2B shows an opposite side of the exemplary control portion shown in FIG. 2A. The exemplary control portion 50 is similar to the control portion 50 shown in FIGS. 1B and 1D and may be operated in the manner shown in those figures, or in ways that are not explicitly represented in the Figures. The topmost portion of the control portion 50 contains micro controls 50 a. The specifics of the micro controls 50 a will be described in detail below, but in general the micro controls 50 a may control the micro or relatively-finer motion of aspects of the slave portion. For example, the micro controls 50 a may control movements of instruments and/or tools in the slave portion, such as the tool or tools 4 shown in FIGS. 1C-1D, within the operational environment O. In contrast, the macro controls 50 b shown in the lower portion of the device 100 in FIGS. 2A and 2B, may be used to control macro or relatively coarser motions of the slave portion 70. For example, the macro controls 50 b may be used to bring the instrument 4 and/or tools 7 of the slave portion 70 in proximity to the operational environment O from another position (e.g., a position outside of where contact between the instrument and/or tools and an object upon which work is to be performed, or a position where the instrument and/or tools are being serviced). However, as noted above, these definitions are not literal, specific or rigorous and merely serve to give a broad understanding of how various aspects of the invention relate to one another.

The control portion 50 shown in FIG. 2B may have other aspects that give it additional degrees of freedom in the motions that may be transmitted from the user to the slave portion of the device. These additional aspects will be discussed in more detail below. Generally, each degree of freedom corresponds to its own control cylinder 100, as shown in FIG. 2B. For example, the user may grasp the grasper hand assembly 1200 and squeeze the trigger 1220, as well as: move grasper hand assembly 1200 in various directions. These and similar motions define an input force or motion 3 (FIG. 1A) that generally effect a mechanical response in the control cylinders 100, which transmit the mechanical response to the slave portion of the device.

FIG. 3A highlights the micro controls 50 a of the exemplary control portion shown in FIGS. 2A and 2B and FIG. 3B shows the control portion of FIG. 3A in use. FIG. 3A shows several exemplary features of the micro controls 50 a, including a grasper hand assembly 1200, and a trigger 1220 for interacting with the user. Generally, the user may grasp the grasper hand assembly 1200, as shown in FIG. 3B, squeeze the trigger 1220. This motion and similar motions generally effect a mechanical response in one or more of the control cylinders 100, also shown in FIG. 3A, which transmit the mechanical response to the slave portion of the device (FIG. 1C).

FIG. 3A also shows a closer view of exemplary spool valves 100 a attached to each of the control cylinders 100 for, among other things, keeping the hydraulic lines filled with fluid. As shown in FIG. 3A, the spool valves 100 a are generally connected to each of the control cylinders 100 on one end and contain a portion of the control fluid communicating between the control cylinder 100 and the slave portion of the device. Although the fluid connections are not explicitly shown in FIG. 3A, they may be made by any suitable connection. Generally, one connects a hydraulic line at the inlets in the spool valves 100 a and connects the other end of the hydraulic line to a corresponding control cylinder on the slave portion of the device. In this configuration, each degree of freedom typically has one control cylinder in the control portion and one corresponding control cylinder in the slave portion. These respective control cylinders may be connected using the spool valves 100 a described in U.S. Provisional Patent Appl. No. 61/297,630 titled “HYDRAULIC DEVICE INCLUDING SPOOL VALVE,” hereby incorporated herein by reference. As described in more detail in U.S. Provisional Patent Appl. No. 61/297,630 titled “HYDRAULIC DEVICE INCLUDING SPOOL VALVE,” fully incorporated herein by reference, another purpose of the spool valve of the instant invention, among others, is to control fluid communication between the control cylinder 100 and the slave portion of the device. Although spool valves 100 a may not be shown in conjunction with each control cylinder 100 shown herein, it is to be understood that a spool valve 100 a may be used with any of the control cylinders 100 discussed herein. Note that the control portion 50 in FIGS. 2A, 2B and 3A, and each of its components, is purely exemplary of one of the types of control portions that may be used in conjunction with the present invention. It is to be understood that aspects of the present invention can be used in conjunction with a variety of other devices, including other control portions.

FIGS. 4A and 4B highlight the macro controls 50 b of the exemplary control portion shown in FIG. 2A. As shown in FIG. 4A, the macro controls 50 b may include three control cylinders 100. The control cylinders 100 may actuate different degrees of freedom in the device 1000. Exemplary degrees of freedom will be discussed in more detail below. Each of the control cylinders 100 has an associated transmission assembly 405, 505 and 605, respectively, for example, including gear assemblies. Generally, the transmission assemblies of the macro controls 50 b serve to translate user motion to the control cylinders 100, which then translate that motion into the pressurization or release of hydraulic fluid in communication with corresponding control cylinders in the slave portion of the device 70. Although specific gear assemblies 405, 505 and 605 will be shown in the context of device 1000, it is to be understood that they may be replaced by any suitable transmission or gear assembly, or other actuating assembly, that serves to translate user motion to the control cylinders 100. It is to be further understood that the number of control cylinders and gear assemblies shown in FIGS. 4A and 4B is merely exemplary. Additional degrees of freedom may be added by adding new control cylinders 100. Alternatively, not all of the control cylinders 100 shown in FIGS. 4A and 4B need be present or operational in the macro controls 50 b.

Generally speaking, the macro controls 50 b actuate macro motions in the slave portion of the device. Such macro motions may include, but are not limited to, positioning instrument 4 and/or tool 7 appropriately so that it may perform operations on a specific area of the operating environment O. FIGS. 4A and 4B also show an anchor 610 that may serve to anchor the control portion 50 to a fixed object or another portion of the device 1000. For example, the anchor 610 may simply be a peg (as shown in FIGS. 4A and 4B) for anchoring the control portion 50 to a stand, desk, table or bedside by fitting into a peg receptacle on one of these objects. Alternatively, the anchor 610 may include a clamp, screws or fasteners for anchoring the control portion 50 to an object. In some aspects, anchor 610 may allow fixed relative movement between control portion 50 and the object to which it is anchored. For example, the anchor 610 may allow relative rotational movement between different fixed positions between the control portion 50 and the object to which it is anchored in order to fix. For example, such relative movement may be desired for user comfort in positioning the system relative to the user's body. In other aspects, anchor 610 may fixedly position the control portion 50 to the object to which it is anchored.

FIGS. 4C and 4D show the macro controls in FIGS. 4A and 48 in use by a user U. As shown in FIGS. 4C and 4D, the user may grip the grasper hand assembly 1200 and rest his/her elbow in arm holder assembly 1100. The user U may generally actuate the macro controls 50 b using the forearm and the elbow in conjunction with the arm holder assembly 1100, or other portions of his/her body. The details of the interaction will be discussed below. It is noted that the macro controls 50 b and micro controls 50 a shown herein are merely exemplary. The macro controls 50 b and micro controls 50 a may include other aspects and features not explicitly identified herein relating to the control and actuation of motion. For example, the macro controls 50 b and micro controls 50 a may include additional levers, triggers, screws buttons or latches. The macro controls 50 b and micro controls 50 a may also include additional aspects that make the user more comfortable (e.g., cushions or padding, fans or cooling devices).

Interaction of Control Portion with Control Cylinders

It should be noted that a number of different mechanisms for actuating control cylinders are disclosed herein. While certain variations of actuation mechanisms may be more appropriate for certain applications, it is to be understood that most of the actuation mechanisms discussed here are, to some extent, interchangeable. That is, it would be possible to apply a particular actuation mechanism (including various components for manipulating mechanical motion including gears, levers, screw members, linkages, pistons or other components) for another suitable purpose. Many of the actuation mechanisms discussed in the context of a particular degree of freedom may also be employed to actuate different degrees of freedom discussed herein and different degrees of freedom that are not discussed herein. It is to be understood that such variations fall within the scope of the present invention.

FIGS. 5A and 5B illustrate an exemplary mechanism for controlling actuation of force or motion, in the form of a control cylinder 100. As shown in FIGS. 5A and 5B, the control cylinder 100 includes an outer cylinder 101 which, can include a control cylinder shaft 101 a inside an inner cylinder 102. Upon apply force or motion to a macro control 50 a and/or a micro control 50 b, a corresponding control cylinder 100 may be actuated, for example, through one or More levers and/or gears, from the retracted position shown in FIG. 5A to the extended position shown in FIG. 5B. It should be understood, however, that control cylinder 100 is one of a plurality of possible actuation mechanisms that may be used to perform the functions described herein. For example, other actuation mechanisms may include one or any combination of mechanical actuators, hydraulic actuators, magnetic actuators, etc.

As noted above, an exemplary control cylinder 100 includes an outer cylinder 101 and an inner cylinder 102. The inner cylinder 102 is free to move within the outer cylinder 101, while the outer cylinder 101 is connected to a shaft 101 a, where the shaft 101 a is in mechanical communication with a corresponding macro control 50 a or micro control 50 b of the control portion 50. The movements of the control portion 50, described above, cause the outer cylinder 101 to move longitudinally with respect to the stationary inner cylinder 102.

A piston 101 b, attached to a shaft 101 a, moves within the inner cylinder 102. The distal end of the shaft 101 a is configured to be capable of attachment to the piston 101 b, while the proximal end of the shaft 101 a is configured to be capable of attachment to the outer cylinder 101. A fluid 20, such as air, saline, water, oil, etc., is located in the inner cylinder 102 in front of the piston 101 b. When the control portion 50 is moved as described above, the outer cylinder 101 moves forward, thereby moving the shaft 101 a and the piston 101 b. Fluid 20 exits the inner cylinder 102 through an outlet, creating a hydraulic pressure at a point in the distal end of the device. Additional fluid 20, displaced from a slave cylinder, enters to the back of the piston 101 b through an inlet, thereby keeping the volume of the fluid 20 in the system constant. When the control portion 50 is moved to a first end position, the control cylinder 100 is in its retracted position, FIG. 5A. In this position, the piston 101 b is at the distal end of the inner cylinder 102. The fluid 20 is in the back of the piston 101 b.

Generally, the control cylinder 100 slides back and forth within the inner cylinder 102 as shown in FIGS. 5A and 5B. In this way, among others, the control portions use the control cylinder 100 to channel the mechanical force from the user to the instrument 4 and/or tool 7. Generally speaking, devices actuated by the control cylinder 100 are referred to as the “slave” portion of the device. These devices may include instruments 4 and/or tools 7 such as mechanical grippers, lever arms, cutting tools, grasping tools and any other suitable devices. The mechanical force can be used in any number of suitable ways by the slave portion of the devices. For example, the control portions can be used to conduct surgical procedures, move objects or to mechanically provide force for any suitable number of applications. For example, the control portions may be coupled to various surgical apparatus (e.g., clamps, shears, needles, etc.) for performing a surgical operation.

In some aspects, control cylinders 100 may include clutch mechanisms (not shown) that shunt inadvertent over-forcing of the macro or micro controls away from the hydraulic systems in order to prevent damage to components. Exemplary clutch mechanisms are described in Applicant's co-pending U.S. Provisional Patent Appl. No. 61/298,714 titled “OVERFORCE MECHANISM.”

Control cylinders 100, such as those shown in FIGS. 5A and 5B, can be used to drive complex mechanical systems in conjunction with other control cylinders. For example, one control cylinder may be actuated by the control system of FIG. 2B and communicate fluid, ultimately, with one or more other control cylinders in the slave portion of the device. Coupling of the hydraulics between the control cylinders in the master and the slave portions of the device may be accomplished by a variety of means including by directly connecting hydraulic lines, by use of a number of suitable connectors, valves and other fixtures. However, it may be advantageous for the connection to contain a de-coupling mechanism so that the slave and control portions can be hydraulically de-coupled from one another when not in use. Further, as many of the lines and connections used in surgical hydraulic systems and other similar hydraulic systems can allow evaporation of the hydraulic fluid, it is also advantageous for connectors to provide a mechanism of replenishing the hydraulic fluid. Exemplary de-coupling mechanisms and fluid replenishment mechanisms are described in Applicant's co-pending U.S. Provisional Patent Appl. No. 61/297,630 titled “HYDRAULIC DEVICE INCLUDING SPOOL VALVE.”

In summary, in some aspects, some of the actuated mechanical devices, such as the one shown in FIGS. 1A, 2B and 2C, may contain control portions with a single control cylinder or control portions with multiple control cylinders. These control portions with a single control cylinder or control portions with multiple control cylinders may serve to allow a user, such a surgeon, to actuate mechanical operations in another portion of the device. For example, the control portions with a single control cylinder or control portions with multiple control cylinders may actuate and move various tools for the implementation of surgery. Generally speaking, the control portions (e.g., control portions with a single control cylinder or control portions with multiple control cylinders) are part of the control portion of the device and the various instruments and/or tools are part of the slave portion of the device. The connections between the control and slave portions are primarily hydraulic in nature to allow transmission of mechanical forces between the two portions. However, other connections (e.g., electrical, pneumatic, electromagnetic, and optical) may also be present in order to transmit various types of information between the two portions of the device.

FIGS. 6A and 6B give an overview of exemplary variations of the slave portion 70 of variations of the present invention. As shown in FIGS. 6A and 6B, the slave portion 70 may include, among other components, an Extension/Retraction actuator portion 40 and a Pivoting/Swivel actuator portion 30 that may relate to the macro motions discussed in detail below. The instrument 4 and/or tool 7 that may be included in the slave portion 70 may have a variety of components and functionalities. For example, the instrument and/or tool may include graspers, scalpels, scissors, tweezers and any other component suitable for the application. Further, the instrument 4 and/or tool 7 may include or correspond to any number of suitable control cylinders 100 appropriate for the application. The control cylinders 100 in the instrument 4 and/or tool 7 may be independently actuated or may work in tandem. Also, the instrument 4 and/or tool 7 may include multiple functions and multiple instruments/tools. The instrument 4 and/or tool 7 may also be modular in nature and may allow the substitution or exchange of various components with various functionalities.

As shown in FIGS. 6A and 6B the slave portion 70 may include one or more control cylinders 100 depending on the number of desired motions and/or on the system configuration. FIG. 6A shows the exemplary slave portion 70 fixed to a stand 2 and FIG. 68 represents the exemplary slave portion 70 without a stand 2. The configurations shown in FIGS. 6A and 6B are merely exemplary. For example, there may be additional control cylinders 100 to those shown in the figures, wherein one or more control cylinder 100 corresponds to one or more degrees of freedom in the system. For example, in one aspect, each of the slave control cylinders 100 generally corresponds to at least one of the master control cylinders 100 of the control portion 50 of the device shown in FIGS. 2A and 2B. However, there need not be a one to one correspondence between control cylinders 100 in the slave and master or control portions. Each of the control cylinders 100 in the slave portion 70 is hydraulically coupled to some aspect of the master control portion 50, such as being hydraulically coupled to a corresponding master control cylinders 100.

FIG. 6A shows exemplary hydraulic lines 600 that may connect aspects of the slave 70 and control portions 50 as described above and in other ways. Hydraulic lines L may be of any suitable material or have any suitable configuration. For example, hydraulic lines 600 may include plastic, rubber or other elastic material. Aspects of the hydraulic lines 600 may also include metal in any suitable form, including metal sheathing, weaving or metal reinforcement, for example, to control expansion of the lines under pressure, which thereby controls the transfer of motion or force from the master to the slave portion. Aspects of the hydraulic lines may also include other suitable materials including various polymeric materials as well as foils, glasses, or any other suitable material. Portions of the hydraulic lines 600 may be rigid and others may be suitably flexible, as needed. Portions of the hydraulic lines 600 may be transparent or opaque. Variations of the invention disclosed herein may include any suitable number of hydraulic lines of any suitable construction or configuration. The hydraulic lines 600 (see, e.g.; FIG. 1C) may also be made from a variety of materials, including plastics, rubbers and/or including various fibers or metal weavings. The hydraulic lines 600, corresponding control cylinders and spool valves may be of any suitable size and have any suitable inner and outer diameters for the particular applications. One type of hydraulic line may be used, or there may be a variety of types of hydraulic lines used in the same device 1000, for example, depending on the pressure of a given line. It is noted that drawings represented here of components relating to this invention are not necessarily to scale. In fact, the components and principles articulated here may operate on several different size scales alternatively or simultaneously.

The hydraulic fluid used with hydraulic lines 600 and with other exemplary variations of the present invention may be any suitable hydraulic fluid. This suitable hydraulic fluid may be, for example, any number of suitable oils, such as mineral oil. The hydraulic fluid may also be a fluid that is medically benign, such as saline or water. Any other suitable fluid may also be used, including fluids that are not medically benign.

Connections between the hydraulic lines may be obtained using spool valves, other valves, or other suitable hydraulic connections. These connections may include the use of O-rings or seal valves, for example. The connections may include other components (e.g., caps, pipes, sockets).

FIGS. 7-11 show variations of the device 1000. Note that the device 1000 shown in FIGS. 7-11 includes several aspects not shown in FIGS. 1B-6B. For example, FIGS. 7-11 show a casing 140 covering certain aspects of the slave portion 70 of the device. It is to be understood that any of the gears, cylinders or other components shown herein may be covered by such a casing during operation or storage. The casing 140 may serve to protect the components from dust, wear or inadvertent contact with other objects, for example. The slave portion 70 of the device shown in FIGS. 7-11 also includes grip handles 2 a and knobs 2 b for fixing the slave portion 70 to some other object, including a stand 2. The grip handles 2 a and, knobs 2 b may also be used to adjust the position of a slave portion 70. Further, the slave portion 70 of FIGS. 7-11 includes a single instrument 4 having a connected tool 7. It is to be understood that multiple instruments 4 and/or tools 7 may also be connected. In addition a single device may include multiple slave portions 70 and/or multiple control portions 50 as needed.

Macrocontrols and Macro Motions Overview

FIG. 12A shows an overview of three exemplary macro degrees of freedom in a variation of the slave portion of the device in accordance with aspects of the present invention. FIG. 12B shows an overview of how the three exemplary macro degrees of freedom shown in FIG. 12A may be actuated in the control portion. These figures and discussion are meant as an introduction to the three exemplary degrees of freedom which will be discussed in more detail with their associated controlling and actuating mechanisms in the following section. It should be noted that, while the exemplary degrees of freedom are useful for certain applications, they are not meant to be exhaustive. Other degrees of freedom are within the scope of the invention. Indeed, it is possible to modify the existing apparatus as described to encompass either additional or fewer degrees of freedom, as needed. All such modifications should be considered within the scope of the present invention.

In FIG. 12A, one of the exemplary macro degrees of freedom shown is Forward/Reverse Pivoting of the instrument 4 and related components. Forward/Reverse Pivoting may allow instrument 4 to pivot about a central pivot point, such as Pivot Point 2 shown in FIG. 12A, in plane P1. This particular degree of freedom is useful for, among other things, positioning the instrument 4 about a particular area of interest in an operational environment O. For example, the Forward/Reverse Pivoting degree of freedom can be used to position a tool 7, such as a scalpel, on the end of the instrument 4 in a position appropriate for the making of an incision. Alternatively, Forward/Reverse Pivoting degree of freedom can be used to position tweezers on the end of the instrument 4 in a position appropriate for grasping a particular object (e.g., an organ or tissue). FIG. 12B shows how the Forward/Reverse Pivoting may be actuated, in particular by a swinging motion of the user's forearm in conjunction with the micro controls 50 a.

In FIG. 12A, another of the exemplary macro degrees of freedom shown is Lateral of the instrument 4 and related components. The Lateral Swivel may allow instrument 4 to swivel about axis A in plane P2. This particular degree of freedom is useful for, among other things, positioning the instrument 4 about a particular area of interest in an operational environment O. This particular degree of freedom may, for example, compliment the Forward/Reverse Pivoting motion such that the instrument 4 and related components are able to assume 180° of motion in the two orthogonal planes P1 and P2 that are perpendicular to axis A. The Lateral Swivel degree of freedom can be used, for example, to position a scalpel on the end of the instrument 4 in a position appropriate for the making of an incision. Alternatively, Forward/Reverse Pivoting degree of freedom can be used to position tweezers on the end of the instrument 4 in a position appropriate for grasping a particular object (e.g., an organ or tissue). FIG. 12B shows how the Forward/Reverse Pivoting may be actuated, in particular by a lateral sweeping motion of the user's forearm in conjunction with the micro controls 50 a.

In FIG. 12A, another of the exemplary macro degrees of freedom shown is Extension/Retraction of the instrument 4 and related components. Extension/Retraction may allow instrument 4 to be brought closer to or further away from the operational environment O. This particular degree of freedom may, for example, allow the instrument 4 to be retracted a safe distance from objects in the operating environment while it is repositioned using the Forward/Reverse Pivoting and Lateral Swivel motions. Once the instrument 4 has been repositioned, it may be brought back in contact or in close proximity with the operational environment O using the Extension/Retraction degree of freedom. FIG. 12B shows how Extension/Retraction may be actuated, in particular by a forward or backward motion of the micro control 5 a assembly and corresponding motion of portions of the macro control assembly 50 b.

Details of the Macro Controls

FIGS. 13A-17E highlight details of the macro controls and their operation. In the exemplary variation of the invention 1000 shown in FIGS. 13A-17E there are three macro controls controlling three associated macro degrees of freedom. However, it is to be understood that this is merely exemplary. There could be any suitable number of macro controls controlling any associated number of degrees of freedom. Further, although in the exemplary variation each macro control has an associated control cylinder 100 and an associated single degree of freedom, it is to be understood that other combinations are possible within the scope of the invention. For example, macro controls may act in combination on the same control cylinder or on the same combination of control cylinders. This may control or more degrees of freedom simultaneously.

Clutch Mechanism

FIG. 13A highlights an optional clutch safety mechanism 300 that prevents or enables operation of the macro controls 50 b and FIG. 13B shows a close up of the clutch safety mechanism 300 from the opposite viewpoint. Generally, the clutch safety-mechanism 300 includes two major components, an upper portion 300 a and a lower portion 300 b. Note that the control cylinder 100 belonging to the lower portion 300 b is related to one of the three degrees of freedom of the macro controls 50 b. This control cylinder is shown in a different position in FIGS. 13A and 13B. However, the relative position of the control cylinder 100 is not necessarily related to the operation of the clutch safety mechanism 300. The clutch safety mechanism 300 can temporarily disconnect the hydraulic systems between the macro controls 50 b and their corresponding control cylinders 100 on the slave portion of the device. Alternatively, the clutch safety mechanism 300 may be purely mechanical and disconnect the macro controls 50 b from their corresponding control cylinders 100 on the slave portion in a purely mechanical fashion.

Generally, in one aspect, when the device 1000 is not in operation, the clutch safety mechanism 300 is in the upright position shown in FIG. 13A. The upright position may be displaced from horizontal by the arc D1. The arc D1 may be any suitable length. The upright position generally disengages the macro controls 50 b from their corresponding control cylinders 100 on the slave portion. As shown in FIG. 13A, the upright position may be the default position taken by clutch safety mechanism 300 when not in use. The upright position may be assumed automatically, such as by a biasing mechanism, which may include one or more of a spring, a lever, a hinge and/or other suitable mechanisms for positioning the clutch to disconnect the hydraulic system when the user's arm is not present in arm holder assembly 1100 to press downwardly on the upper portion 300 a of the clutch safety mechanism 300. In the upright position, hydraulic lines between the macro controls 50 b and their corresponding control cylinders 100 in the slave portion may be disconnected, for example, by valves, plungers or other mechanics 300 c that interrupt the fluid communication between the two portions. Disconnecting the macro controls 50 b from their corresponding control cylinders 100 in the slave portion can prevent inadvertent actuation of the degrees of freedom associated with the macro controls 50 b when the system 1000 is not in use. This can prevent damage to they system by, for example, inadvertent actuation of one of the control cylinders 100 of the slave portion bringing the instrument 4 of the slave portion into contact with an object in the operational environment O, or a storage environment, that causes damage (e.g., from scraping, gouging or smashing contact). Disengaging the macro controls 50 b in the upright position prevents such contact or inadvertent motion. It should be understood, however, that the clutch mechanism may be configured to disengage the hydraulic system at positions of the macro controls 50 b other than the upwardly biased position.

In one aspect of an upwardly biased clutch mechanism, when the user places his or her arm in the arm holder assembly 1100 and presses downwardly on the cradle, this downward force is transmitted to the upper portion 300 a of the clutch safety mechanism 300. This force then brings the lower 300 b and upper 300 a portions of the clutch safety mechanism 300 into contact. This generally positions the valves, plungers or other mechanics 300 c to allow either hydraulic or mechanical communication between the macro controls 50 b and their corresponding cylinders 100 in the slave portion of the device. The engaged position is shown, for example, in FIG. 14A. Typically, in the engaged position, the upper 300 a and the lower 300 b portions of the clutch safety mechanism 300 are in direct contact. However, other configurations are also within the scope of the invention. For example, the clutch safety mechanism 300 may be adjustable so that the engaged position can be adjusted according to user preference and/or to maximize user comfort. Alternatively, the engaged position may be accessed by more complicated motions than simply pressing down on the arm holder assembly 1100. For example, the engaged position may be accessed by simultaneously pressing down on the arm holder assembly 1100 and moving the control portion in a given direction, such as laterally (not shown). More complicated motions to access the engaged position may also be possible.

First Exemplary MACRO Degree of Freedom: Forward/Reverse Pivoting.

FIG. 14A-14E highlight a first exemplary degree of freedom of the macro controls associated with a forward translation of the slave portion. FIGS. 14A-14C show how the motion may be actuated in the macro controls 50 b and FIGS. 14D and 14E show an exemplary resultant motion in the slave portion and FIG. 14F highlights that motion along the curved track of the slave portion. FIGS. 15A and 15B show the resultant forward/reverse pivoting motion of the tool of the slave portion.

As shown in FIGS. 14A-14C, the user may actuate a forward translation of the slave portion by swiveling the entire micro controls 50 a throughout arc D2. As shown in FIGS. 14A-14C, the micro controls 50 a may swivel about pivot point 401. FIG. 14C shows an exemplary gear setup 405 that may be used to translate this swiveling motion of the micro controls 50 a about the arc D2 to a linear motion of a control cylinder 100. For example, swiveling the micro controls 50 a about pivot point 401 may cause gear 405 a to turn and engage gear 405 b. Gear 405 b may then engage linear gear 405 c which can be fixed to the control cylinder 100, as shown in FIG. 14C. This gear, motion, in either direction, then may cause the piston of the control cylinder show in FIG. 14C to move in the lateral direction D3, pumping hydraulic fluid to a corresponding control cylinder 100 on the slave portion of the device (as shown and discussed in the context of FIG. 5).

The control cylinder 100, the micro controls 50 a and the gear setup 405 may be configured such that any suitable combination of motions is possible. For example, moving the micro controls 50 a in a clockwise direction D2 about pivot point 401 may ultimately cause hydraulic fluid to be pumped to the slave portion of the device. In this case, moving the micro controls 50 a in a counter clockwise direction D2 about pivot point 401 may ultimately cause hydraulic fluid to be pumped to the control portion of the device. Alternatively, moving the micro controls 50 a in a clockwise direction D2 about pivot point 401 may ultimately cause hydraulic fluid to be pumped to the control portion of the device. In this case, moving the micro controls 50 a in a counter clockwise direction D2 about pivot point 401 may ultimately cause hydraulic fluid to be pumped to the slave portion of the device.

FIGS. 14D and 14E show how the motion of the micro controls 50 a described in FIGS. 14A-4C may be translated into motion of the slave portion of the device. Hydraulic fluid is either pumped in or out of the control cylinder 100 in FIGS. 14D and 14E on the slave portion of the device according to motion of the micro controls 50 a discussed above with reference to FIGS. 14A-14C.

In FIG. 14D, the control cylinder 100 receiving or expelling hydraulic fluid associated with the first exemplary degree of freedom is shown in an inset. Typically, the control cylinder 100 will be housed in a casing 140, which is also shown in FIG. 14D. FIG. 14E shows the setup in FIG. 14D without the casing 140 and without the instrument 4. As shown in FIGS. 14D and 14E, the control cylinder 100 may be mechanically coupled to a track 450 in which a chain 450 a may translate. The chain 450 a and the track 450 are shown in more detail with respect to the casing 140 in FIG. 14F.

Generally, the chain 450 a may be coupled on one end to an instrument holder 4 a. An exemplary coupling 450 b is shown in more detail in FIG. 14E: The coupling 450 b may have any suitable form for connecting the instrument holder 4 a to the chain 450 a such that, for example, the instrument holder 4 a moves as the chain 450 a slides along the track. For example, coupling 450 b may include a carriage having wheels that ride along track 450. In some aspect, track 450 may include a groove or a rail to guide the carriage and/or wheels. In turn, the other end of the chain 450 a may be coupled to the control cylinder 100 shown in FIG. 14E such that motion of the control cylinder 100 (see FIG. 5) pushes or pulls the chain 450 a along the track 450.

In general, a piston head and shaft of the control cylinder may move along the direction D4 shown in FIGS. 14D and 14E, causing the chain 450 a to slide along direction D5 shown in FIGS. 14D-14F. FIG. 15A shows an exemplary resultant motion of the instrument 4 and the instrument holder 4 a in response to actuation by the motion of the control cylinder 100 along direction D4. FIG. 15B highlights the pivoting motion of the coupling 450 b along direction D5. As shown in FIGS. 15A and 15B, the structure of the curved shape of the track 450 causes coupling 450 b and, therefore, the instrument 4, to pivot about an effective Pivot Point. For example, as the chain 450 a moves away from the casing 140 along direction D5, the mechanical coupling 450 b sweeps through a series of positions P1-P5 about the Pivot Point 1. This causes the instrument 4 and the instrument holder 4 a sweep through the series of positions about Pivot Point 2. Since the chain may be positioned such that the mechanical coupling 450 b adopts any of the positions P1-P5, or any other suitable position along D5, the instrument 4 may effectively adopt any position about the Pivot Point 2. This may allow the instrument 4 and the user U to operate on any portion of the operational environment O that may be accessed with such motion.

Second Exemplary MACRO Degree of Freedom: Lateral Swivel

FIG. 16A-16E highlight a second exemplary degree of freedom of the macro controls associated with a lateral swivel of the slave portion. FIGS. 16A-16C show how the motion may be actuated in the macro controls 50 b and FIGS. 16D and 16E show an exemplary resultant motion in the slave portion. FIG. 16F highlights an exemplary screw mechanism that may actuate the exemplary lateral swivel motion.

As shown in FIGS. 16A-16E, the user may actuate a lateral swivel, e.g. a rotation in a plane substantially perpendicular to axis A (see FIGS. 16D and 16E) of the slave portion by swiveling the entire micro controls 50 a throughout arc D6 about pivot point 501. FIG. 16C shows an exemplary gear setup 505 that may be used to translate this swiveling motion of the micro controls 50 a about the arc D6 to a horizontal motion of a control cylinder 100. The INSET in FIG. 16C shows another view of exemplary gears in the gear setup 505. For example, swiveling the micro controls 50 a may swivel gear 505 a shown in the INSET. Gear 505 a may then engage gear 505 b, which in turn can engage linear gear 505 c, which can be fixed to the control cylinder 100. This series of gear motion, in either direction, then may cause the piston of the control cylinder 100 to move in the lateral direction D7, pumping hydraulic fluid to a corresponding control cylinder 100 on the slave portion of the device (as shown and discussed in the context of FIG. 5).

The control cylinder 100, the micro controls 50 a and the gear setup 505 may be configured such that any suitable combination of motions is possible. For example, moving the micro controls 50 a in a clockwise direction along arc D6 about pivot point 501 may ultimately cause hydraulic fluid to be pumped to the slave portion of the device. In this case, moving the micro controls 50 a in a counter clockwise direction along arc D6 about pivot point 501 may ultimately cause hydraulic fluid to be pumped to the control portion of the device. Alternatively, moving the micro controls 50 a in a clockwise direction along arc D6 about pivot point 501 may ultimately cause hydraulic fluid to be pumped to the control portion of the device. In this case, moving the micro controls 50 a in a counter clockwise direction along arc D6 about pivot point 501 may ultimately cause hydraulic fluid to be pumped to the slave portion of the device.

FIGS. 16D and 16E show how the macro motion described in FIGS. 16A-C may be translated into motion of the slave portion of the device. In an aspect, an exemplary setup in FIG. 16D includes two control cylinders 100 (one is shown in the inset because it would otherwise be obscured by other components, and the other is visible). In this aspect, in between the control cylinders is a screw member 550 that is attached to a shaft 550 a. Hydraulic fluid is either pumped in or out of the control cylinders 100 in FIGS. 16D and 16E on the slave portion of the device according to macro motions discussed above with reference to FIGS. 16A-16C.

More specifically, in FIG. 16D, the control cylinders 100 receiving or expelling hydraulic fluid associated with the second exemplary degree of freedom are shown. FIG. 16E shows the setup in FIG. 16D without the casing 140 and without the instrument 4. As shown in FIGS. 16D and 16E, the control cylinders 100 may be coupled to a screw member 550, itself coupled to a shaft 550 a. Axis A is the axis of rotation for the shaft 550 a. The shaft 550 a may additionally be coupled to a track 450 via coupling 550 c, such as a link. Coupling 500 c between the shaft 550 a and the track 450 allows motion in the screw to ultimately be translated to the instrument 4 because the instrument 4 is coupled to the instrument holder 4 a, which is movably connected to the track 450.

The coupling 550 c may have any suitable form for connecting shaft 550 a to track 450 such that, for example, rotating the shaft 550 a in the direction D8 about axis A ultimately rotates the track 450 in the same direction. Since the instrument 4 and holder 4 a are coupled to the track 450, this motion ultimately turns the instrument 4 and holder 4 a in the direction D8 as well.

FIG. 16F shows a more detailed view of the screw member and its coupling to the control cylinders 100. In addition to being coupled to the shaft 550 a, the screw member 550 may have threads 550 d that mate with opposing threads in a screw receiving member 552. Generally, though not exclusively, the screw receiving member 552 is coupled to the two control cylinders 100 such that when the two control cylinders 100 are moved in response to the flow of hydraulic fluid from actuation of the control portion of the device, the screw receiving member 552 moves with the control cylinders 100. In general, the control cylinders 100 may move along the direction D9 (FIG. 16E) causing the screw member 550 to rotate in direction D8, which ultimately correspondingly rotates instrument 4.

The shaft 550 a may be rotated such that the instrument 4 is positioned at any angle in the 360 decrees of rotation along D8 about axis A. This may allow the instrument 4 and the user U to operate on any portion of the operational environment O that may be accessed with such motion.

Third Exemplary MACRO Degree of Freedom: Extension/Retraction

FIG. 17A-17E highlight a third exemplary degree of freedom of the macro controls associated with an extension/retraction of the part of the slave portion. FIGS. 17A-17C show how the motion may be actuated in the macro controls 50 b and FIGS. 17D and 17E show an exemplary resultant motion in the slave portion.

As shown in FIGS. 17A-17E, the user may actuate an extension or retraction of the slave portion by translating the macro controls 50 b along direction D10. As shown in FIGS. 17A-17C, the macro controls 50 b can include two portions 600 a and 600 b that may move relative to each other, and relative to static portion 300 b, as shown in FIG. 17A. FIG. 17C shows an exemplary gear setup 605 that may be used to translate the macro controls 50 b along the direction D10 to actuate control cylinder 100.

For example, translating the macro control portions 600 a and 600 b as shown in FIGS. 17A and 17B along direction D10 may cause gears in the gear setup 605 to turn. In the exemplary variation shown in FIGS. 17A-17C, static portion 300 b is held stationary with respect to anchor 610, while both macro control portions 600 a and 600 b are allowed to move with respect to anchor 610. However, it is to be understood that other configurations are also possible. Anchor 610 may be fixed to another portion of the device, to a stand or to another immobile or mobile object. On the other hand, macro control portion 600 a may be fixed to the micro controls 50 a, as shown in FIG. 17C. Generally, the control cylinder 100 may have one end fixed to macro control portion 300 b and the other fixed to macro control portion 600 c such that relative motion of these two components causes either compression or expansion of the control cylinder (e.g., as shown in FIG. 5). When the micro controls 50 a are moved along direction D10 (FIG. 17C), the macro control portion 600 a may be moved along the same direction causing a relative translation of 600 a with respect to macro control portion 600 b. This, in turn, may compress or open the control cylinder 100 thereby expelling or drawing in hydraulic fluid to the control portion and having the opposite effect on the corresponding control cylinder in fluid communication in the slave portion.

The control cylinder 100, portions 300 b, 600 a, 600 b and the gear setup 605 may be configured such that any suitable combination of motions is possible. For example, moving portions 600 a and 600 b away from one another along direction D10 may ultimately cause fluid to be pumped to the slave portion of the device. In this case, moving portions 600 a and 600 b in an opposite direction, e.g., towards one another along direction D10, may ultimately cause fluid to be pumped to the control portion of the device. Alternatively, moving portions 600 a and 600 b toward one another along direction D10 may ultimately cause hydraulic fluid to be pumped to the slave portion of the device. In this case, moving portions 600 a and 600 b in an opposite sense, e.g., away from one another along direction D8, may ultimately cause hydraulic fluid to be pumped to the control portion of the device.

FIGS. 17D and 17E show how the motion of portions 300 b, 600 a, 600 b and the gear setup 605 described in FIGS. 17A-C may be translated into motion of the slave portion of the device. In the exemplary setup shown in FIG. 17D there is one control cylinder 100 connected to the Extension/Retraction actuator portion 40. Fluid is either pumped in or out of the control cylinder 100 in FIGS. 170 and 17E on the slave portion of the device according to motion of portions 300 b, 600 a, 600 b and the gear setup 605 discussed above with reference to FIGS. 17A-17C.

In FIG. 17D, the control cylinder 100 in the Extension/Retraction actuator portion 40 receives or expels fluid associated with the third exemplary degree of freedom. FIG. 17E shows the setup in FIG. 17D without the instrument 4 or the instrument holder 4 a. As shown in FIG. 17D, the instrument 4 and the instrument, holder 4 a may be coupled to control cylinder 100 in the Extension/Retraction actuator portion 40 via coupling 650 a, such as a linkage. Coupling 650 a may connect the control cylinder 100 in the Extension/Retraction actuator portion 40 and the instrument holder 4 a in a manner that allows motion in the control cylinder 100 in the Extension/Retraction actuator portion 40 to be translated to the instrument 4 because the instrument 4 is coupled to the instrument holder 4 a.

For example, in one aspect, instrument holder 4 a may include coupling 650 a fixedly connected to instrument 4 at a first position, and a coupling 650 b movably connected to instrument 4 at a second position. Coupling 650 b may be fixed to a base 40 a of Extension/Retraction actuator portion 40 via a linkage 650 c and coupling 450 a, such as a wheeled carriage. As such, based on actuation of Extension/Retraction actuator portion 40, coupling 650 a translates such actuation to extend or retract instrument 4 relative to coupling 650 b. Thus, the connections between Extension/Retraction actuator portion 40 and instrument 4 may be configured to allow extension/retraction of instrument 4 at a fixed position controlled by the position of coupling 650 b.

For example, instrument holder 4 a and/or the couplings 650 a, 650 b, and 650 c may have any suitable form for connecting the instrument 4 to the control cylinder 100 in the Extension/Retraction actuator portion 40 such that, for example, moving the control cylinder 100 in the direction D11 moves the instrument 4 4 in direction D12, which may be the same direction as D11. In this aspect, direction D12 corresponds to a longitudinal axis of instrument 4, and such movement is referred to as an extension or retraction of instrument 4, e.g. relative to an operational environment O (see FIG. 1). Thus, in one aspect, the control cylinder 100 in the Extension/Retraction actuator portion 40 may move along the direction D11 shown in FIGS. 17D and 17E causing the instrument 4 to move along direction D12, as shown in FIGS. 17D-17E. This may allow the instrument 4 and the user U to operate on any portion of the operational environment O that may be accessed with such motion.

Microcontrols and Micro Motions Overview

In this section, the micro controls and associated micro motions will be discussed in brief. The details of micro controls and associated micro motions will be discussed more thoroughly with respect to their actuating mechanisms in the section that follows. Although the control cylinders of the micro controls are numbered differently than the control cylinders 100 associated with the macro controls, it is to be understood that aspects of all control cylinders discussed herein are, in principle, interchangeable. Therefore, each feature and related mechanism discussed in the context of control cylinders 100 may apply equally well to the control cylinders of the micro controls and the instrument and/or tool discussed below. Similarly, each feature and related mechanism discussed in the context of the control cylinders of the micro controls and the tool discussed below may apply equally well to the control cylinders 100. Similarly, any of the hydraulic components discussed herein are, in principle, interchangeable. All such changes, substitutions and modifications are to be considered within the scope of the present invention.

FIG. 18A shows an overview of four exemplary micro degrees of freedom in an instrument 4 and/or tool 7 in a variation of the slave portion of the device in accordance with aspects of the present invention. FIG. 18B shows an overview of how the four exemplary micro degrees of freedom shown in FIG. 18A may be actuated in the control portion. The four exemplary degrees of freedom will be discussed in more detail below. Note that FIG. 18A shows several exemplary control cylinders 1410, 1510, 1610 and 1710 that may be used with the exemplary degrees of freedom discussed herein as well as with additional exemplary degrees of freedom. It should be noted that, while the exemplary degrees of freedom are useful for certain applications, they are not meant to be exhaustive. Other degrees of freedom are within the scope of the invention. Indeed, it is possible to modify the existing apparatus as described to encompass either additional or fewer degrees of freedom, as needed. All such modifications should be considered within the scope of the present invention.

In FIG. 18A, one of the exemplary micro degrees of freedom shown is the Forearm Rotation 1800 of the instrument 4 and related components. Forearm Rotation 1800 may allow instrument 4 to rotate about a primary axis 1901 of the instrument 4. This particular degree of freedom is useful for, among other things, positioning the instrument 4 about a particular area of interest in an operational environment O. For example, the Forearm Rotation 1800 degree of freedom can be used to position a tool 7, such as scalpel, on the end of the instrument 4 in a position appropriate for the making of an incision. Additionally, for example, the Forearm Rotation 1800 degree of freedom can be used to sweep a cutting motion with the scalpel on the end of the instrument 4. In another example, the Forearm Rotation 1800 degree of freedom can be used to position a tool 7, such as tweezers, on the end of the instrument 4. In a position appropriate for grasping a particular object (e.g., an organ or tissue). FIG. 18B shows how the Forearm Rotation 1800 degree of freedom may be actuated, in particular by a rotating motion of the user's forearm in conjunction with the micro controls 50 a.

Also in FIG. 18A, another one of the exemplary micro degrees of freedom shown is the Wrist Bend 1801 of the instrument 4 and related components. Wrist Bend 1801 may allow instrument 4 to bend with respect to the primary axis 1901 of the instrument 4. This particular degree of freedom is useful for, among other things, positioning a portion of the instrument 4 and/or a tool 7 about a particular area of interest in an operational environment O. For example, the Wrist Bend 1801 degree of freedom can be used to position a scalpel on the end of the instrument 4 in a position appropriate for the making of an incision. For instance, the Wrist Bend 1801 degree of freedom can be used to sweep a cutting motion with scalpel on the end of the instrument 4. In another example, the Wrist Bend 1801 degree of freedom can be used to position tweezers on the end of the instrument 4 in a position appropriate for grasping a particular object (e.g., an organ or tissue). FIG. 18B shows how the Wrist Bend 1801 degree of freedom may be actuated, in particular by a bending motion of the user's wrist in conjunction with the micro controls 50 a.

Further, in FIG. 18A, two additional exemplary micro degrees of freedom shown are Tip Rotation 1802 and Tip Grasp 1803 of the instrument 4 and related components. Tip Rotation 1802 may allow instrument 4 and/or tool 7 to rotate about primary axis 1901, or to rotate about a secondary axis 1902 formed after bending a portion of instrument 4 relative to primary axis 1901. Tip Grasp 1803 may allow instrument 4 and/or tool 7 to bend with respect to the primary axis 1901 of the instrument 4, or to bend about a secondary axis 1902 formed after bending a portion of instrument 4 relative to primary axis 1901. Further, for example, Tip Grasp 1803 may allow a relative bending or pivoting of two corresponding instrument or tool portions, e.g. pincher arms, to grasp or release an item. These particular degrees of freedom are useful for, among other things, positioning the instrument 4 and/or tool 7 about a particular area of interest in an operational environment O. For example, the Tip Rotation 1802 and Tip Grasp 1803 degrees of freedom can be used to position a scalpel on the end of the instrument 4 in a position appropriate for the making of an incision. Additionally, for example, the Tip Rotation 1802 and Tip Grasp 1803 degrees of freedom can be used to sweep a cutting motion with scalpel on the end of the instrument 4. In another example, the Tip Rotation 1802 and Tip Grasp 1803 degrees of freedom can be used to position tweezers on the end of the instrument 4 in a position appropriate for grasping or releasing a particular object (e.g., an organ or tissue). FIG. 18B shows how the Tip Grasp 1803 degree of freedom may be actuated, in particular by gripping certain aspects of the micro controls 50 a that will be described in more detail below. FIG. 188 shows how the Tip Rotation 1802 degree of freedom may be, actuated, in particular by rotating certain aspects of the micro controls 50 a that will be described in more detail below.

Micro Controls

FIG. 19 shows exemplary micro controls 50 a in accordance with aspects of the present invention. The micro controls 50 a may include an arm holder assembly 1100 and a grasper hand assembly 1200 connected by a central frame assembly 1300. The arm holder assembly 1100, grasper hand assembly 1200 and central frame assembly 1300 may be configured to allow various inputs 2 (FIG. 1), such as linear and/or rotational movements, to generate corresponding outputs 11 (FIG. 1) that result in the above-described micro motions.

In one variation of the present invention, the micro controls 50 a control four degrees of freedom, including a forearm rotate, a Wrist Bend 1801, a Tip Rotation 1802 and grasp motions (see FIG. 18A). The user places an arm into the arm holder assembly 1100 and inserting index and middle fingers through finger loops 1212 and 1214 provided on a hand grasper 1210, which is supported at the distal end of the micro controls 50 a. A user may generally actuate the degrees of freedom of the system by moving one or more aspects of the micro controls 50 a, including the arm holder assembly 1100 and components of the grasper hand assembly 1200. As shown in FIG. 18B, the user may rotate the entire micro controls 50 a to actuate the Forearm Rotation 1800 degree of freedom. As also shown in FIG. 18B, the user may rotate an aspect of the grasper hand assembly 1200 to actuate the Wrist Bend 1801 degree of freedom and rotate another aspect of the grasper hand assembly 1200 to actuate the Tip Rotation 1802 degree of freedom. Further, FIG. 18B also shows that the user may trigger or squeeze other aspects of the grasper hand assembly 1200 in order to actuate the Tip Grasp 1803 degree of freedom. These motions will be discussed in more detail below.

The micro controls 50 a are attached to a lower control assembly, which controls the other three degrees of freedom, namely the larger macro motions of extending the slave unit 1500 in and out of the patient and the two tilt axes, forward/backward and left/right (not shown).

Movements of the micro controls 50 a are translated into hydraulic motion by controls that include one or more cylinders, such as a set of master cylinders, a tip rotate master cylinder 1410, a tip grasp master cylinder 1420, a wrist bend master cylinder 1430 and a forearm rotation master cylinder 1440. The master cylinders 1410, 1420, 1430 and 1440 are hydraulically connected to a set of slave cylinders to translate the forearm, wrist and finger motions of the user into mechanical controlling motions of a surgical slave unit 1500. The master cylinders 1410, 1420, 1430 and 1440 use various methods of translation, such as link arrangements and screw pistons, for example, to convert rotational and/or linear movement into a hydraulic pressure applied to the slave cylinders. Moreover, the master cylinders 1410, 1420, 1430 and 1440 may be provided with a clutch mechanism (not shown) to disengage the translation of motion when such motion reaches a threshold, e.g. to prevent aggressive or overreaching movements of the micro controls 50 a. In particular, the clutch mechanism automatically disengages function of the master cylinders 1410, 1420, 1430 and 1440 in the event an excessive pressure is generated, preventing damage to the hydraulics of the device 1000 and possible detrimental impact on the operational environment O (FIG. 1), such as on a patient.

First Exemplary MICRO Degree of Freedom: Forearm Rotation 1800

In an aspect, arm holder assembly 1100 is connected to central frame assembly 1300 to provide relative rotation about a Forearm Rotation axis F. For example, the central frame assembly 1300 may include a primary support plate 1310, a forward center axle support 1312, a rear center axle support 1314, an upper rack beam 1320, and a lower center beam 1330. A center axle 1340 is rotatably supported by the forward and rear center axle supports, 1312 and 1314, respectively, which are both fixed on one side to the primary support plate 1310. Forward and rear hinge brackets, 1342 and 1344, respectively, are fixed to a lower surface of the upper rack beam 1320. The center axle 1340 extends through the hinge brackets 1342, 1344, which are connected to the center axle 1340 so that the upper rack beam 1320 rotates the center axle 1340 about a forearm axis of rotation F when the forearm of a user (not shown) rotates.

As shown in FIG. 19, the forearm rotation master cylinder 1440 is situated substantially below the arm holder assembly 1100 and supported on the lower center beam by a bracket 1442. Rotation of the forearm is translated into rotation of the center axle 1340 about the Forearm Rotation axis F which, in turn, may drive a pendulum gear 1445 fit to the distal end of the center axle 1340 extending forward of the forward center axle support 1312. The pendulum gear 1445 may drive a turn gear 1447 to drive a forearm screw piston 1449, for example, into or out of the Forearm rotation master cylinder 1440, depending on the direction of rotation indicated by the forearm. The screw piston 1449 may be provided with a sealed nut (not shown) on an end internal to the Forearm rotation master cylinder 1440, for example, the linear movement of which is caused by rotation of the screw piston 1449. The rotational motion of the forearm is thus translated by the screw piston 1449 into a linear piston motion which may compress or decompress a hydraulic fluid provided in the Forearm rotation master cylinder 1440. Pressure is transferred from the Forearm rotation master cylinder 1440 to a corresponding slave cylinder to drive a rotation of the slave unit 1500 (see FIG. 5) through a hydraulic line (not shown), for example. The hydraulic line may comprise flexible tubing. Although flexible, the tubing may be manufactured from a hard plastic, or with expansion resisting components such as metal fibers, to avoid extensive expansion of the tubing due to pressure and extended use. Furthermore, in some aspects, the tubing may be supported with a metal-reinforced sleeve, for example, to prevent rupture of the thin wall while maintaining a degree of flexibility for increased modularity and mobility of the device 1000.

The hydraulic fluid is preferably sterilized distilled water, however, a saline solution, a perfluorinated hydrocarbon liquid, air or any other physiologically compatible fluid could also be used. A “physiologically compatible fluid” is a fluid that once exposed to tissues and organs, does not exacerbate a reaction, such as a rash or immune response, in the patient, and does not adversely interfere with the normal physiological function of the tissues or organs to which it is exposed. In addition, a physiologically compatible fluid can remain in a patient's body or in contact with a tissue or an organ without the need to remove the fluid.

Although movements of the micro controls 50 a are described herein as being hydraulically actuated to control associated movements of a slave apparatus, the movements may generate electrical signals that are sent through wires to control the slave portions of the device 1000. The electrical signal, for example, may actuate a motor in the corresponding slave module to actuate the motion desired. In addition, motors may be used to enhance a hydraulically actuated movement, thus assisting a user in achieving the designated motion with less user applied force, which may be of benefit to the increased endurance of a user, for example, during long procedures.

Second Exemplary MICRO Degree of Freedom: Wrist Bend 1801

In accordance with aspects of the present invention, the Wrist Bend 1801 motion of the slave unit 1500 (see FIG. 18A) may be controlled by the Wrist bend master cylinder 1430. As shown in FIGS. 19-21, the grasper hand assembly 1200 includes a grasper frame 1230. One end of the grasper frame 1230 is connected to the upper rack beam 1320 at a Wrist Bend 1801 pivot point 1240 and at the other end to the hand grasper 1210 at a Tip Rotation 1802 pivot point 1250. A Wrist Bend 1801 link member 1260 is provided between the grasper frame 1230 and the Wrist bend master cylinder 1430. The user may actuate a Wrist Bend 1801 motion in the slave unit 1500 (see FIG. 18A) by pivoting the grasper frame 1230 around a Wrist Bend 1801 axis W of the Wrist Bend 1801 pivot point 1240. The pivoting of the grasper frame 1230 may push or pull the Wrist Bend 1801 link member 1260, which, in turn, may linearly push or pull a piston in the Wrist bend master cylinder 1430. The corresponding change in hydraulic pressure in the Wrist bend master cylinder 1430 is transferred to a slave cylinder for actuating the Wrist Bend 1801 motion in the slave unit 1500. As shown in FIG. 23, the Wrist bend master cylinder 1430 is secured to the upper rack beam 1320 by a bracket 1435.

Third and Fourth Exemplary MICRO Degrees of Freedom: Rotational and Grasp Control of Tip

Aspects of the present invention may provide rotational and grasp control of the tip of the slave member 1500 (see FIG. 18A). As shown in FIGS. 19-21, the user may insert fingers through finger loops 1212 and 1214 provided on the hand grasper 1210. To actuate the Tip Grasp 1803 motion, the user may squeeze or push the trigger 1220, causing the trigger 1220 to rotate about the Tip Grasp 1803 axis G in a counterclockwise or clockwise motion, toward or away from the user. The trigger 1220 may be formed with an extension 1220 connected to the tip grasp master cylinder 1420, so that pivoting of the trigger 1220 around the grasp axis G may push or pull the extension 1221, which, in turn, may linearly push or pull a piston in the tip grasp master cylinder 1420. The corresponding change in hydraulic pressure in the tip grasp master cylinder 1420 is transferred to a slave cylinder for actuating the Tip Grasp 1803 motion in the slave unit 1500 as shown in FIG. 18A.

To assist the user in pushing the trigger 1220, the trigger 1220 may be provided with a flange 1222 that extends away from the main body of the trigger 1220. The flange 1222 provides a mechanism by which the user may, for example, use a thumb to apply pressure against the flange 1222 to force the trigger 1220 to rotate away from the user, creating the reverse motion from squeezing the trigger 1220. For example, squeezing the trigger 1220 may cause the tip graspers 1730 on the slave unit to close in vice-like fashion (see FIG. 18A), while pushing the trigger 1220 through pressure to the flange 1222 may cause the tip graspers to open. Accordingly, a user may control the speed and degree of the tip grasping motion by applying more or less force to the trigger 1220 and setting the relative position of the trigger 1220 in relation to being either fully open or fully closed.

As shown in FIG. 19, the hand grasper 1210 may be free to rotate around the tip rotate axis T to provide rotational control of the tip of the slave member 1500 (see FIG. 18A). The hand grasper 1210 may be pivotally mounted onto the grasper frame at the tip rotate pivot point 1250. A sector gear 1251 may be coupled to the hand grasper 1210 so that rotation of the hand grasper 1210 about the tip rotate pivot point 1250 causes the sector gear 1251 to rotate counterclockwise or clockwise. The sector gear 1251 may work in tandem with a multiplier gear 1253 and a second sector gear 1254 attached to the tip rotate master cylinder 1410 to translate the rotational movement of the hand grasper 1210 into linear motion of a screw piston, for example, in the tip rotate master, cylinder 1410. As shown in FIG. 20, the tip rotate master cylinder 1410 may mount onto the grasper frame 1230 and the grasper frame 1230 may provide rotatable support to the gears 1253 and 1254. Accordingly, the pivoting of the hand grasper 1210 about the Tip Rotation 1802 pivot point 1250 may linearly push or pull the screw piston, for example, in the tip rotate master cylinder 1410. The corresponding change in hydraulic pressure in the tip rotate master cylinder 1410 is transferred to a slave cylinder for actuating the tip rotate motion in the slave unit 1500 (see FIG. 18A).

Support Structure and Adjustability of the Micro Controls

The arm holder assembly 1100 has a support structure that includes left and right mounting plates, 1110 and 1120, respectively, supporting an arm bracket 1130. A horizontal arm rest 1140, a vertical left arm support 1142 and a vertical right arm support 144 are mounted to the arm bracket 1130 to effectively cradle and support the arm of the user during a procedure. The horizontal arm rest 1140 may be formed to be adjustable left or right by sliding along the arm bracket 1130.

The arm holder assembly 1100 may be adjusted both horizontally and vertically. The left and right mounting plates 1110, 1120 are provided with vertical slots 1111, 1121. A lateral support 1150, e.g., a bolt, may be provided that extends through the vertical slots 1111 and 1120 on the left and right mounting plates 1110, 1120 and may include a locking nut 1152 (see FIG. 21) and a handle clamp 1154. By releasing the handle clamp 1154, the arm holder assembly 1100 may be raised or lowered. By locking the handle clamp 1154, the arm holder assembly 1100 may be locked into a set position. As shown in FIG. 21, the left and/or right mounting plates 1110, 1120 may be provided with a scale 1115 or similar markings to indicate the relative adjusted height of the arm holder assembly 1100. In this manner, the user may note the height indication for quick and easy vertical adjustment of the arm holder assembly 1100, each time using the device 1000. As shown in FIG. 21, the lateral support 1150 connects the arm holder assembly 1100 to the horizontal upper rack beam 1320 through a brace mechanism 1170. The brace mechanism 1170 engages and surrounds the upper rack beam 1320 while permitting linear movement of the brace mechanism 1170 along the upper rack beam 1320. By sliding the arm holder assembly 1100 longitudinally along the upper rack beam 1320, a horizontal distance between the arm holder assembly 1100 and the hand grasper 1210 may be adjusted. Similar markings may be provided on the upper rack beam 1320, for example, to allow quick and easy horizontal adjustment of the arm holder assembly 1100. The arm holder assembly 1100 may thus be adjusted both vertically and horizontally to provide a comfortable and customizable arrangement for supporting the user's arm during the length of a procedure.

Although aspects of the invention have been shown primarily as being manually and/or hydraulically actuated, it is to be understood that aspects of the invention may alternatively be electrically actuated or actuated via computer interface. Aspects of the present invention may be implemented using hardware, software or a combination thereof and may be implemented in one or more computer systems or other processing systems. In one variation, aspects of the present invention are directed toward one or more computer systems capable of carrying out the functionality described herein. An example of such a computer system 2500 is shown in FIG. 23. For example, computer system 2500 may receive input 3 (FIG. 1) and generate output 11 using electrical control signals to control motors to perform the above-described movements.

Computer system 2500 includes one or more processors, such as processor 2504. The processor 2504 is connected to a communication infrastructure 2506 (e.g., a communications bus, cross-over bar, or network). Various software aspects are described in terms of this exemplary computer system. After reading this description, it will become apparent to a person skilled in the relevant art(s) how to implement aspects of the present invention using other computer systems and/or architectures.

Computer system 2500 can include a display interface 2502 that forwards graphics, text, and other data from the communication infrastructure 2506 for from a frame buffer not shown) for display on the display unit 2530. Computer system 2500 also includes a main memory 2508, preferably random access memory (RAM), and may also include a secondary memory 2510. The secondary memory 2510 may include, for example, a hard disk drive 2512 and/or a removable storage drive 2514, representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive 2514 reads from and/or writes to a removable storage unit 2518 in a well-known manner. Removable storage unit 2518, represents a floppy disk, magnetic tape, optical disk, etc., which is read by and written to removable storage drive 2514. As will be appreciated, the removable storage unit 2518 includes a computer usable storage medium having stored therein computer software and/or data.

In alternative variations, secondary memory 2510 may include other similar devices for allowing computer programs or other instructions to be loaded into computer system 2500. Such devices may include, for example, a removable storage unit 2521 and an interface 2520. Examples of such may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an erasable programmable read only memory (EPROM), or programmable read only memory (PROM)) and associated socket, and other removable storage units 2521 and interfaces 2520, which allow software and data to be transferred from the removable storage unit 2521 to computer system 2500.

Computer system 2500 may also include a communications interface 2524. Communications interface 2523 allows software and data to be transferred between computer system 2500 and external devices. Examples of communications interface 2523 may include a modem, a network interface (such as an Ethernet card), a communications port, a Personal Computer Memory Card International Association (PCMCIA) slot and card, etc. Software and data transferred via communications interface 2523 may be in the form of signals 2528, which may be electronic, electromagnetic, optical or other signals capable of being received by communications interface 2524. These signals 2528 are provided to communications interface 2523 via a communications path (e.g., channel) 2526. This path 2526 carries signals 2528 and may be implemented using wire or cable, fiber optics, a telephone line, a cellular link, a radio frequency (RF) link and/or other communications channels. In this document, the terms “computer program medium” and “computer usable medium” are used to refer generally to media such as a removable storage drive 2514, a hard disk installed in hard disk drive 2512; and signals 2528. These computer program products provide software to the computer system 2500. Aspects of the present invention are directed to such computer program products.

Computer programs (also referred to as computer control logic) are stored in main memory 2508 and/or secondary memory 2510. Computer programs may also be received via communications interface 2524. Such computer programs, when executed, enable the computer system 2500 to perform the features in accordance with aspects of the present invention, as discussed herein. In particular, the computer programs, when executed, enable the processor 2504 to perform the features of certain aspects of the present invention. Accordingly, such computer programs represent controllers of the computer system 2500.

In one variation where aspects of the present invention are implemented using software, the software may be stored in a computer program product and loaded into computer system 2500 using removable storage drive 2514, hard drive 2512, or communications interface 2524. The control logic (software), when executed by the processor 2504, causes the processor 2504 to perform the functions in accordance with aspects of the present invention, as described herein. In another variation, aspects of the present invention are implemented primarily in hardware using, for example, hardware components, such as application specific integrated circuits (ASICs). Implementation of the hardware state machine so as to perform the functions described herein will be apparent to persons skilled in the relevant art(s).

Although the invention has been described with reference to various aspects of the present invention and examples with respect to a surgical instrument, it is within the scope and spirit of the invention to incorporate or use with any suitable mechanical device. Further, while the invention has been described with reference to a surgeon, the invention may be used with another user, depending on circumstances in which the invention is used. Thus, it should be understood that numerous and various modifications may be made without departing from the spirit of the invention. 

1. An articulating surgical device, comprising: a control portion capable of receiving an input; a slave portion coupled to the control portion configured to receive the input from the control portion and generate a corresponding output, wherein the slave portion comprises a first slave end coupled to the control portion and a second slave end; an instrument coupled to the second slave end; and a surgical tool coupled to the instrument; wherein the slave portion includes a first series of actuators configured to actuate at least one macro motion in the instrument and the slave portion further includes a second series of actuators configured to actuate at least one micro motion in the surgical tool.
 2. The articulating surgical device of claim 1, wherein the output is provided via a hydraulic communication.
 3. The articulating surgical device of claim 1, wherein the macro and micro motions generated via the output of the slave portion corresponding to the received input.
 4. The articulating surgical device of claim 1, wherein a coupling mechanism couples operation of the surgical tool and instrument to the control portion via the slave portion and is configured to transfer tactile feedback from the surgical tool to the control portion.
 5. The articulating surgical device of claim 4, wherein the coupling mechanism is configured to actuate the first and second actuators of the second slave end.
 6. The articulating surgical device of claim 5, wherein the coupling mechanism is hydraulically operated.
 7. The articulating surgical device of claim 1, wherein the control portion includes a clutch mechanism for de-coupling the slave portion from the control portion.
 8. The articulating surgical device of claim 1, wherein the first series of actuators include a forward/reverse pivoting actuator operable to produce a forward/reverse pivoting macro motion of the instrument.
 9. The articulating surgical device of claim 8, further including a chain mechanism, wherein: a first end of the chain mechanism is mechanically coupled to the forward/reverse pivoting actuator; a second end of the chain mechanism is mechanically coupled to the instrument; the chain mechanism is operable configured to slide along a curved track; and the forward/reverse pivoting actuator is configured to actuate the forward/reverse pivoting macro motion of the instrument by causing the chain mechanism to slide along the curved track.
 10. The articulating surgical device of claim 1, wherein the first series of actuators includes a lateral swivel actuator configured to actuate a lateral swivel macro motion of the instrument.
 11. The articulating surgical device of claim 10, further including a screw mechanism, wherein: a first end of the screw mechanism is mechanically coupled to the lateral swivel actuator; a second end of the screw mechanism is mechanically coupled to a shaft oriented along a shaft axis, the shaft being mechanically coupled to the instrument; and the lateral swivel actuator is configured to actuate the lateral swivel pivoting macro motion of the instrument by causing the screw mechanism to rotate about the shaft axis.
 12. The articulating surgical device of claim 1, wherein the first series of actuators include an extension/retraction actuator operable to produce an extension/retraction macro motion of the instrument.
 13. The articulating surgical device of claim 12, further including an instrument holder mechanism, wherein: a first end of the instrument holder mechanism is mechanically coupled to the extension/retraction actuator; a second end of the instrument holder mechanism is mechanically coupled to the instrument at a first end that is opposite a second end of the instrument, wherein the second end is coupled to the surgical tool; the instrument holder mechanism is configured to move along a path that is substantially along a direction including the first and second ends of the instrument; and the extension/retraction actuator is configured to actuate the extension/retraction macro motion of the instrument by causing the instrument holder to move along the path of the instrument holder mechanism.
 14. The articulating surgical device of claim 1, wherein the second series of actuators include a forearm rotation actuator configured to actuate a forearm rotation of the surgical tool.
 15. The articulating surgical device of claim 14, further including a wrist bend mechanism having a wrist joint and a wrist bend actuator, wherein: a first end of the wrist bend mechanism is mechanically coupled to the surgical tool; a second end of the wrist bend mechanism is mechanically coupled to the wrist bend actuator; the wrist joint connects first and second ends of the wrist bend mechanism; and the wrist bend mechanism is configured to bend the first end of the wrist bend mechanism about the second end of the wrist bend mechanism using the wrist joint as a pivot point.
 16. The articulating surgical device of claim 15, wherein the wrist bend actuator includes at least one control cylinder that is operated remotely.
 17. The articulating surgical device of claim 16, wherein the wrist bend mechanism includes a control cylinder on at least one side of the wrist joint.
 18. The articulating surgical device of claim 1, wherein the second series of actuators includes a tip rotation actuator configured to actuate a tip rotation micro motion of the surgical tool.
 19. The articulating surgical device of claim 18, further including a tip rotation mechanism, wherein: a first end of the tip rotation mechanism is mechanically coupled to the surgical tool; a second end of the tip rotation mechanism is mechanically coupled to the tip rotation actuator; and the tip rotation mechanism is configured to rotate the first end of the tip rotation mechanism about a tip rotation axis.
 20. The articulating surgical device of claim 19, wherein the tip rotation actuator includes at least one control cylinder that is operated remotely.
 21. The articulating surgical device of claim 1, wherein the second series of actuators includes a tip grasp actuator configured to actuate a tip grasp micro motion of the surgical tool.
 22. The articulating surgical device of claim 21, wherein the tip grasp actuator includes at least one control cylinder that is operated remotely via micro controls.
 23. The articulating surgical device of claim 21, further including a wrist bend mechanism, wherein: a first end of the wrist bend mechanism is mechanically coupled to the surgical tool; a second end of the wrist bend mechanism is mechanically coupled to a wrist bend actuator; a wrist joint connecting the first and second ends of the wrist bend mechanism; and the wrist bend mechanism is configured to bend the first end of the wrist bend mechanism about the second end of the wrist bend mechanism using the wrist joint as a pivot point.
 24. The articulating surgical device of claim 23, wherein the tip grasp mechanism is configured to open and close the pincer arms when the wrist bend mechanism has bent the first end of the wrist bend mechanism about the second end of the wrist bend mechanism.
 25. The articulating surgical device of claim 21, further including a forearm rotation mechanism, wherein: a first end of the forearm rotation mechanism is mechanically coupled to the surgical tool; a second end of the forearm rotation mechanism is mechanically coupled to the instrument; and the forearm rotation mechanism is configured to rotate the surgical tool about an axis.
 26. An articulating surgical device, comprising: a control portion capable of receiving a hydraulically communicated input; a slave portion coupled to the control portion configured to receive the hydraulically communicated input from the control portion and generate a corresponding output, wherein the slave portion comprises a first slave end coupled to the control portion and a second slave end; a means for facilitating surgical motion coupled to the second slave end; and a means for performing surgery coupled to the means for facilitating surgical motion; wherein the slave portion includes a first means for actuating at least one motion in the means for facilitating surgical motion and the slave portion further includes a second means for actuating at least one motion in the means for performing surgery.
 27. A method of operating an articulating surgical device, comprising: receiving, at a slave portion, a hydraulic input from a control portion; generating, at a slave portion, a corresponding output to the received input; actuating a first series of actuators to move an instrument operationally coupled to the slave portion, based on the output; and actuating a second series of actuators to move a surgical tool operationally coupled to the instrument, based on the operation of the first series of actuators.
 28. The method of operating an articulating surgical device of claim 27, wherein the instrument is moved in a forward/reverse pivoting manner.
 29. The method of operating an articulating surgical device of claim 27, wherein the instrument is moved in a laterally swiveling manner.
 30. The method of operating an articulating surgical device of claim 27, wherein the instrument is moved in an extending/retracting manner.
 31. The method of operating an articulating surgical device of claim 27, wherein the surgical tool is moved in a rotating manner.
 32. The method of operating an articulating surgical device of claim 27, wherein a tip of the surgical tool is moved in a rotating manner.
 33. The method of operating an articulating surgical device of claim 27, wherein pincer arms of the surgical tool are moved in an opening/closing manner. 